The Manufacturing and Innovation Hub, which is part of Northumbria Healthcare NHS Foundation Trust, has partnered with Warwick Med to manufacture reusable and personalised theatre hats — improving patient safety and reducing anxiety in operating theatres across the UK.

About Eco Ninjas

Eco Ninjas (by Warwick Med) is dedicated to improving healthcare environments for both patients and staff. Their mission is to help hospital theatres make the transition from disposable theatre caps to reusable high-quality fabric hats that feature a removable badge on the front displaying the healthcare professional's name and job title.

The Idea Behind the Badges

The idea came from Danielle Checketts, Managing Director of Eco Ninjas and a former nurse. When training in an operating theatre, Danielle was asked to write her name and role onto her disposable theatre hat so she could be identified by staff and the patient. Inspired by this simple moment, she found there was a gap in the market for latex-free, personalised theatre hats — and developed the innovation of attaching badges to the hat as an alternative to embroidery.

These badges are made from durable polyurethane, which can be easily cleaned and decontaminated after use, supporting high hygiene standards. They have also undergone rigorous testing to support safety requirements.

Danielle said: "As both a former nurse and patient, I understand deeply the importance of clear communication in reducing patient anxiety. These hats are more than an innovation — they are about bringing humanity back into our healthcare interactions."

The Northumbria Partnership

The Northumbria Healthcare Manufacturing and Innovation Hub partnered with Warwick Med in 2023 to manufacture the reusable theatre hats. Product Development Manager Michelle Triplow-Jones said: "We're really pleased to be working with Danielle and the team at Warwick Med to produce the reusable theatre hats. We know that a hospital can be an intimidating place for patients, and these hats are a fantastic way to put patients at ease and improve their experience."

Environmental Impact

An average 20-theatre hospital usually disposes of around 100,000 caps per year — most of which go to landfill, with some being incinerated, posing significant risks to the environment. Reusable theatre hats can be taken home to wash and reused for approximately 3 years, ultimately improving sustainability within healthcare and making a tangible difference to each trust's environmental footprint.